U.S. patent number 11,302,987 [Application Number 15/470,382] was granted by the patent office on 2022-04-12 for material for dissipating heat from and/or reducing heat signature of electronic devices and clothing.
This patent grant is currently assigned to LAT ENTERPRISES. The grantee listed for this patent is LAT Enterprises, Inc.. Invention is credited to Carlos Cid, Laura Thiel.
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United States Patent |
11,302,987 |
Thiel , et al. |
April 12, 2022 |
Material for dissipating heat from and/or reducing heat signature
of electronic devices and clothing
Abstract
Systems, methods and articles having a heat-shielding or
blocking, heat-dissipating and/or heat signature-reducing material
layer or coating are disclosed. In one example, the heat-shielding
or blocking, heat-dissipating and/or heat signature-reducing
material completely covers the interior of a housing having a
plurality of battery cells removably disposed therein. Other
examples include a heat-shielding or blocking, heat-dissipating
and/or heat signature-reducing material layer having anti-static,
anti-radio frequency (RF), anti-electromagnetic interference (EMI),
anti-tarnish, and/or anti-corrosion materials and properties that
effectively protect battery-operated devices and/or the batteries
that power them from damage or diminished operation.
Inventors: |
Thiel; Laura (Raleigh, NC),
Cid; Carlos (Raleigh, NC) |
Applicant: |
Name |
City |
State |
Country |
Type |
LAT Enterprises, Inc. |
Raleigh |
NC |
US |
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Assignee: |
LAT ENTERPRISES (Raleigh,
NC)
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Family
ID: |
1000006237105 |
Appl.
No.: |
15/470,382 |
Filed: |
March 27, 2017 |
Prior Publication Data
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Document
Identifier |
Publication Date |
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US 20170229692 A1 |
Aug 10, 2017 |
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Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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14516127 |
Oct 16, 2014 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H01M
50/24 (20210101); A41D 31/085 (20190201); H01M
50/20 (20210101); A41D 31/265 (20190201); H01M
2220/30 (20130101); A41D 19/01529 (20130101) |
Current International
Class: |
A41D
31/08 (20190101); A41D 31/26 (20190101); H01M
50/24 (20210101); H01M 50/20 (20210101); A41D
19/015 (20060101) |
Field of
Search: |
;429/163,164,175,176 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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2003174179 |
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Jun 2003 |
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JP |
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2004103248 |
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Apr 2004 |
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JP |
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101145898 |
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May 2012 |
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KR |
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101159750 |
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Jun 2012 |
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KR |
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101294972 |
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Aug 2013 |
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KR |
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2013106474 |
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Jul 2013 |
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WO |
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WO-2015181673 |
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Dec 2015 |
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WO |
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Other References
Electropaedia; Battery and Energy Technologies; printout from Jul.
2, 2012; pp. 1-5 (Year: 2012). cited by examiner .
Rechargeable Military Batteries; Epsilor;
https://www.epsilor.com/catalog/Rechargeable/ELI-0414/; accessed
and printed May 8, 2020 (Year: 2020). cited by examiner .
Battery; Merriam-Webster;
https://www.merriam-webster.com/dictionary/battery; accessed and
printed May 8, 2020 (Year: 2020). cited by examiner .
Yunhuan Group; 3 prong Australia AC power cord; archived Jul. 1,
2016;
https://web.archive.org/web/20160701194647/http://www.yunhuanelectric.com-
/Australia-AC-Power-Cord-03.html (Year: 2016). cited by examiner
.
Machine translation of JP 2004-103248; accessed and printed Aug. 7,
2021 (Year: 2004). cited by examiner .
EE-Dan; Repair Your Laptop Power Cord; Instructables.com; published
Jun. 11, 2013;
https://www.instructables.com/Repair-Your-Laptop-Power-Cord/ (Year:
2013). cited by applicant.
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Primary Examiner: Schmiedel; Edward J.
Attorney, Agent or Firm: NEO IP
Parent Case Text
CROSS REFERENCE TO RELATED APPLICATIONS
This application is related to and claims priority from the
following US patent applications: this application is a
continuation-in-part of U.S. application Ser. No. 14/516,127, filed
Oct. 16, 2014, which is incorporated herein by reference in its
entirety.
Claims
The invention claimed is:
1. A battery housing unit comprising: a lid; a base; a plurality of
electrochemical battery cells removably provided within the base,
wherein the plurality of electrochemical battery cells are operable
to store chemical energy; and a layer comprising polyethylene and
copper functionally positioned between the lid and the plurality of
electrochemical battery cells; wherein the base further includes: a
first mounting plaque; a second mounting plaque; a first draw latch
secured to the first mounting plaque; a second draw latch secured
to the second mounting plaque; wherein the first draw latch and the
second draw latch are operable to attach the battery housing unit
to a corresponding catch of a military radio; at least one recessed
portion including at least one recessed hole and at least one
connector; wherein the at least one recessed hole is substantially
circular except for a flat portion of the at least one recessed
hole, wherein the flat portion facilitates installation of the at
least one connector; wherein the at least one connector is secured
in the at least one recessed hole; wherein the at least one
connector includes a keyway, wherein the keyway ensures a correct
orientation of a right angle cable attached to the at least one
connector wherein the keyway angles the right angle cable away from
the first draw latch or the second draw latch; at least one dust
cap to cover the at least one connector; and a coating to protect
the plurality of electrochemical battery cells from electromagnetic
interference.
2. The battery housing unit of claim 1, wherein the coating
comprises copper.
3. The battery housing unit of claim 1, wherein the lid has a
connector.
4. The battery housing unit of claim 1, wherein the base comprises
a composite metal foam.
5. The battery housing unit of claim 1, further including a second
layer comprising polyethylene and copper, wherein the second layer
comprising polyethylene and copper completely covers an interior
surface of the base.
6. The battery housing unit of claim 1, wherein the at least one
dust cap is attached to the base via a lanyard attached the first
mounting plaque or the second mounting plaque.
7. The battery housing unit of claim 6, wherein a length of the
lanyard is shorter than a distance between the first mounting
plaque or the second mounting plaque and a bottom side of the
base.
8. The battery housing unit of claim 1, wherein the layer includes
one or more of a material selected from a group consisting of an
anti-static material, an anti-radiofrequency material, an
anti-electromagnetic interference material, an anti-corrosion
material, an anti-tarnish material, and combinations thereof.
9. The battery housing unit of claim 1, wherein the layer is
positioned between a first substrate and a second substrate.
10. The battery housing unit of claim 1, wherein the layer includes
at least one fold and/or at least one bump.
11. The battery housing unit of claim 1, wherein the base comprises
a unitary and integrally formed piece of plastic formed via
injection molding.
12. The battery housing unit of claim 1, wherein the plurality of
electrochemical battery cells is contained in at least one
casing.
13. The battery housing unit of claim 1, wherein the first mounting
plaque or the second mounting plaque, the first draw latch or the
second draw latch, the at least one recessed hole, and the at least
one connector are on a same side of the battery housing unit
perpendicular to a bottom side of the base, wherein the first
mounting plaque or the second mounting plaque is positioned on the
same side of the battery housing unit perpendicular to the bottom
side of the base, wherein the first draw latch or the second draw
latch is positioned on the same side of the battery housing unit
perpendicular to the bottom side of the base as the first mounting
plaque or the second mounting plaque, wherein the at least one
recessed hole and the at least one connector are on the same side
of the battery housing unit perpendicular to the bottom side of the
base as the first mounting plaque or the second mounting plaque and
the first draw latch or the second draw latch.
14. The battery housing unit of claim 1, wherein the layer further
comprises aluminum.
15. The battery housing unit of claim 1, wherein the base comprises
aluminum, titanium, nickel, magnesium, a microlattice metal, and/or
a composite metal foam.
16. The battery housing unit of claim 1, wherein the correct
orientation of the right angle cable is a thirty-degree angle
relative to the base.
17. The battery housing unit of claim 1, wherein the at least one
recessed portion is located at a bottom of a side of the base and
extends from a bottom edge of the base towards a center of the base
such that the at least one recessed portion includes four interior
sides.
18. The battery housing unit of claim 17, wherein the four interior
sides include a first interior side, a second interior side, a
third interior side, and a fourth interior side, wherein the first
interior side, the second interior side, and the third interior
side include tapered edges, wherein each tapered edge includes a
taper from an interior of the at least one recessed portion to the
side of the base including the at least one recessed portion, and
wherein the fourth interior side includes the at least one recessed
hole.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
The presently invention relates generally to systems and methods of
dissipating heat, shielding objects from external heat and/or
managing heat signatures of objects, including a material for
dissipating heat from and/or reducing the heat signature of
electronic devices and/or clothing.
2. Description of the Prior Art
The military uses various types of portable electronic devices,
such as portable battery-operated radios, which generate heat
during operation, i.e., during normal operation, the devices may be
heat-generating devices. In particular, a malfunctioning device can
cause excessive heating. A drawback of heat-generating devices is
that the heat may be transferred to the person using or carrying
the device, causing uncomfortableness or burns. Another drawback of
heat-generating devices is that the heat may be transferred to
other devices, causing damage to these devices. Further, in
military applications, heat-generating devices may increase the
heat signature of military personnel, making them more prone to
detection by thermal imaging and therefore more prone to
danger.
It is known in the prior art to provide heat dissipating material
or insulating material with heat-generating devices.
Representative prior art patent documents include the
following:
US Publication No. 20110100425 for heat dissipation sheet for the
back face of solar battery module, and solar battery module using
the same by inventors Osamura et al., filed Nov. 1, 2010 and
published May 5, 2011, is directed to a heat dissipation sheet for
the back face of a solar battery module includes a heat dissipation
film, and an adhesive compound layer laminated on one face side of
the heat dissipation film. The heat dissipation film preferably has
a fine bumpy shape on the entire surface of another face. The heat
dissipation film preferably includes a substrate layer in which the
adhesive compound layer is laminated on one face side, and a heat
dissipation layer laminated on another face side of the substrate
layer. The heat dissipation layer preferably includes fine
particles, and a binder for the fine particles.
US Publication No. 20130263922 for back sheet for solar cells and
method for preparing the same by inventors Jung et al., filed Dec.
28, 2011 and published Oct. 10, 2013, is directed to a back sheet
for solar cells including a substrate, a fluororesin layer existing
on one side of the substrate and a heat-dissipating ink layer
existing on the other side of the substrate. Provided also is a
method for preparing the same. The back sheet for solar cells may
have an excellent heat dissipation property as well as a high
durability. Further, the method for preparing the same may allow a
cost-efficient production of solar cells.
US Publication No. 20080223428 for all printed solar cell array by
inventor Zeira, filed Dec. 7, 2005 and published Sep. 18, 2008, is
directed to a method for producing a photovoltaic novelty item.
Conductive polymer solutions and semiconductive oxide dispersions
are formulated into inks that are laid down on top of one another
to produce voltage and current when exposed to light. In addition,
these inks may be printed on novelty items, such as magazine
advertisements or greeting cards, connecting to printed light
emitting graphics.
US Publication No. 20080223431 for foldable solar panel by inventor
Chu, filed Mar. 15, 2007 and published Sep. 18, 2008, is directed
to a foldable solar panel comprising multiple rigid cell
assemblies, multiple folding cell assemblies and multiple primary
flexible seams. Each folding cell assembly has two symmetric
folding cell assembly halves and a flexible secondary seam. The
symmetric folding cell assembly halves are adjacent to each other.
The secondary flexible seam connects adjacent symmetric folding
cell assembly halves and allows them to fold inward onto each
other. A primary flexible seam connects a rigid cell assembly to an
adjacent folding cell assembly to form an absorbing surface. The
primary flexible seams and secondary flexible seams facilitate
folding the foldable solar penal to a small volume to facilitate
transportation or storage, and effectively keep the absorbing
surface from being damaged.
US Publication No. 20090229655 for solar cell by inventor Lee,
filed Mar. 13, 2008 and published Sep. 17, 2009, is directed to a
solar cell. The solar cell defines a receiving room in where at
least a cell unit is located. A transparent cover plate is placed
over the cell unit. In addition, the transparent cover plate
includes a base plate and a structured plate which are adhered to
each other. Wherein, the base plate is made from inflexible
material and the structured plate is made from a photo resin.
Moreover, there are pluralities of convex first patterns disposed
on the incident surface of the structured plate.
SUMMARY OF THE INVENTION
The present invention provides systems, methods and articles having
a heat-shielding or blocking, heat-dissipating and/or heat
signature-reducing material layer or coating for functionally
protecting articles, electronic devices, batteries disposed within
a housing, and human skin in contact with heat-producing objects.
The term "housing" as used throughout this application refers to an
apparatus which holds casing-enclosed batteries (i.e. one or more
sealed individual batteries). In one example, the heat-shielding or
blocking, heat-dissipating and/or heat signature-reducing material
completely covers the interior of a housing having a plurality of
battery cells removably disposed therein. Other examples include a
heat-shielding or blocking, heat-dissipating and/or heat
signature-reducing material layer having anti-static, anti-radio
frequency (RF), anti-electromagnetic interference (EMI),
anti-tarnish, and/or anti-corrosion materials and properties that
effectively protect battery-operated devices and/or the batteries
that power them from damage or diminished operation.
In one embodiment, a housing with sealed battery cells disposed
therein is coated or lined with a heat-shielding or blocking,
heat-dissipating and/or heat signature-reducing material.
Preferably, the heat-shielding or blocking, heat-dissipating and/or
heat signature-reducing material completely covers the interior of
a housing having a plurality of battery cells removably disposed
therein. Other examples include a heat-shielding or blocking,
heat-dissipating and/or heat signature-reducing material layer
having anti-static, anti-radio frequency (RF), anti-electromagnetic
interference (EMI), anti-tarnish, and/or anti-corrosion materials
and properties that effectively protect battery-operated devices
and/or the batteries that power them from damage or diminished
operation.
In another embodiment, the present invention provides an article
for dissipating heat including a heat-dissipating layer; and one or
more substrates disposed in close relation to the heat-dissipating
layer. One aspect of the present invention provides a
heat-dissipating layer including one or more of a material selected
from the group including an anti-static material, an anti-radio
frequency material, an anti-electromagnetic interference material,
an anti-corrosion material, or an anti-tarnish material. Another
aspect of the present invention provides a heat-dissipating layer
that includes a copper shielding plastic or a copper impregnated
polymer.
In one embodiment of systems, methods, and articles of the present
invention, a heat-dissipating material layer is uniformly
distributed as a coating and/or lining on the internal sides of a
housing for battery components for functionally shielding the
batteries disposed in the housing from external heat, dissipating
heat produced by the batteries disposed in the housing and reducing
the heat signature associated therewith.
These and other aspects of the present invention will become
apparent to those skilled in the art after a reading of the
following description of the preferred embodiment when considered
with the drawings, as they support the claimed invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A illustrates a cross-sectional view of one embodiment of
structures that include material for dissipating heat from and/or
reducing heat signature of electronic devices and/or clothing.
FIG. 1B illustrates a cross-sectional view of another embodiment of
structures that include material for dissipating heat from and/or
reducing heat signature of electronic devices and/or clothing.
FIG. 1C illustrates a cross-sectional view of yet another
embodiment of structures that include material for dissipating heat
from and/or reducing heat signature of electronic devices and/or
clothing.
FIG. 1D illustrates a cross-sectional view of yet another
embodiment of structures that include material for dissipating heat
from and/or reducing heat signature of electronic devices and/or
clothing.
FIG. 2A is a view of a radio holder article held in a pouch.
FIG. 2B is a view of the radio holder article of FIG. 2A removed
from the pouch.
FIG. 3 is a perspective view of an example of a flexible solar
panel.
FIG. 4 is an exploded view of an example of a flexible solar
panel.
FIG. 5 is a perspective view of an example of a portable battery
pack.
FIG. 6 is another perspective view of an example of a portable
battery pack.
FIG. 7 is yet another perspective view of an example of a portable
battery pack.
FIG. 8 is a perspective view of an example of a wearable pouch of a
portable battery pack.
FIG. 9 is another perspective view of an example of a wearable
pouch of a portable battery pack.
FIG. 10 is yet another perspective view of an example of a wearable
pouch of a portable battery pack.
FIG. 11 illustrates various other views of wearable pouch of a
portable battery pack.
FIG. 12A illustrates an exploded view of an example of a battery of
a portable battery pack.
FIG. 12B illustrates an exploded view of an example of a battery of
a portable battery pack into which the heat dissipating and/or heat
signature-reducing material is installed.
FIG. 13 is a perspective view of a battery of a portable battery
pack.
FIG. 14 is another perspective view of a battery of a portable
battery pack.
FIG. 15 illustrates an exploded view of an example of a battery
into which the heat dissipating and/or heat signature-reducing
material is installed.
FIG. 16 illustrates a view of an example of a battery base.
FIG. 17 illustrates another view of an example of a battery
base.
FIG. 18A illustrates a top view perspective of the battery lid.
FIG. 18B illustrates a cross-section view of the battery lid.
FIG. 18C illustrates a side view perspective of the battery
lid.
FIG. 18D illustrates another cross-section view of the battery
lid.
FIG. 19A illustrates a top view perspective of the battery
base.
FIG. 19B illustrates a cross-section view of the battery base.
FIG. 19C illustrates a detail view of a part of the cross-section
view of the battery base shown in FIG. 19B.
FIG. 19D illustrates a side view perspective of the battery
base.
FIG. 19E illustrates another cross-section view of the battery
base.
FIG. 19F illustrates another side view perspective of the battery
base.
FIG. 20 illustrates a view of a BA-5590 female connector.
FIG. 21 illustrates a block diagram of a portable power case into
which the heat dissipating and/or heat signature-reducing material
is installed.
FIG. 22 illustrates a block diagram showing the inside of one
embodiment of the portable power case.
FIG. 23 illustrates a block diagram of the connections to the
printed circuit board (PCB).
FIG. 24 illustrates a view of the exterior of one embodiment of the
portable power case.
FIG. 25 illustrates a view of the portable power case showing the
USB ports.
FIG. 26 illustrates one example of the portable power case lined
with material resistant to heat.
FIG. 27A illustrates the access ports of the portable power
case.
FIG. 27B illustrates a keyway of the access ports of the portable
power case.
FIG. 28 illustrates a block diagram of a portable power case in an
ATV with three passengers.
FIG. 29 illustrates a block diagram of a portable power case in an
ATV with four passengers.
FIG. 30 illustrates a block diagram of the battery protector.
DETAILED DESCRIPTION
The present invention provides systems, methods and articles having
a heat-shielding or blocking, heat-dissipating and/or heat
signature-reducing material layer or coating that functions to
protect electronic devices, articles, and/or human skin in contact
with them. In one example, the heat-shielding or blocking,
heat-dissipating and/or heat signature-reducing material completely
covers the interior of a housing having a plurality of battery
cells removably disposed therein. Other examples include a
heat-shielding or blocking, heat-dissipating and/or heat
signature-reducing material layer having anti-static, anti-radio
frequency (RF), anti-electromagnetic interference (EMI),
anti-tarnish, and/or anti-corrosion materials and properties that
effectively protect battery-operated devices and/or the batteries
that power them from damage or diminished operation
In one embodiment of the present invention, the heat-dissipating
layer includes one or more of a material selected from the group
consisting of an anti-static material, an anti-radio frequency
material, an anti-electromagnetic interference material, an
anti-corrosion material, an anti-tarnish material, and combinations
thereof. Preferably, the heat dissipating material layer or coating
includes a copper shielding plastic, and more preferably, the heat
dissipating material layer or coating includes a copper impregnated
polymer.
In alternate embodiments, one substrate is bonded to the
heat-dissipating layer; one substrate is loosely arranged in
relation to the heat-dissipating layer; a first substrate and a
second substrate wherein the heat-dissipating layer is sandwiched
between the first and second substrate, or the first and second
substrates are bonded to the heat-dissipating layer, or the first
and second substrates are loosely arranged in relation to the
heat-dissipating layer, or the first substrate is bonded to the
heat-dissipating layer and the second substrate is loosely arranged
in relation to the heat-dissipating layer. In these various
embodiments, the one or more substrates are flexible, rigid, or a
combination thereof; the one or more substrates include a fabric;
the one or more substrates comprise one or more of glass, plastic,
or metal; or the one or more substrates comprise multi-layer
structures.
In one embodiment of the present invention, the article including a
heat-dissipating material layer is configured to fit inside a
hand-held radio holder. In yet another embodiment, the article
includes a solar panel assembly sandwiched between a first
substrate and the heat-dissipating layer.
In an exemplary embodiment, the heat shielding or blocking, or
heat-dissipating material is used to prevent and/or minimize heat
transfer and the heat signature produced from batteries, as well as
to prevent and/or minimize heat transfer from external
heat-producing articles or objects. Team operations in remote
locations, such as military operations, require radios to allow
team members to communicate about danger, injuries, opportunities,
etc. Without radios in these environments, more people would be
injured or die. However, most radios suitable for these
environments are high powered radios which typically require
lithium ion batteries. While lithium ion batteries are capable of
providing a lot of power, lithium ion batteries have produced a
large amount of heat since their inception. The heat produced from
lithium ion batteries is capable of causing radiation burns to
radio operators, even through layers of clothing. This heat also
increases the heat signature of soldiers, making them more
vulnerable to enemy thermal imaging technology. In extreme cases,
malfunctions in lithium ion batteries cause fires. Heat produced
from lithium ion batteries is also capable of damage the radio
itself or other electronic devices critical to survival.
Additionally, shipping lithium ion batteries or devices with
lithium ion batteries is banned or highly regulated in most parts
of the world due to the risk of overheating and/or fire. What is
needed is a material which can be incorporated within a battery
housing for a with lithium batteries, but not on the batteries
themselves, to prevent the risk of overheating and fire. As lithium
ion batteries were developed in the 1970s and have been in
commercial use since the 1990s, there is a long-felt unmet need for
systems, methods, and apparatuses to reduce, eliminate, or contain
the heat produced from batteries for safer operation of radios and
other electronic devices critical to survival.
None of the prior art provides a housing, base, container, or case
for one or more batteries which dissipates the heat produced by the
one or more batteries during operation, thus reducing the heat
signature of the housing and preventing the housing from heating
and causing discomfort and/or burns to an operator in contact with
the housing.
Certain aspects of the presently disclosed subject matter of the
invention, having been stated hereinabove, are addressed in whole
or in part by the presently disclosed subject matter, and other
aspects will become evident as the description proceeds when taken
in connection with the accompanying illustrative examples and
figures as best described herein below.
Referring now to the drawings in general, the illustrations are for
the purpose of describing a preferred embodiment of the invention
and are not intended to limit the invention thereto.
The present invention provides a material for 1) reducing or
eliminating heat exposure from external objects or other
heat-producing devices; 2) dissipating heat from at least one
battery or heat-producing electronic device; and/or 3) reducing the
heat signature of electronic devices and/or clothing. The heat
blocking or shielding, heat-dissipating, and/or heat
signature-reducing material is incorporated into the housing of a
heat-producing device or battery pack housing, or any article of
clothing or fabric. In one example, a heat shielding or blocking,
heat-dissipating, and/or heat signature-reducing material layer is
sandwiched between two substrates, wherein the substrates may be
flexible, rigid, or a combination of both flexible and rigid.
When applied to clothing, the heat blocking or shielding,
heat-dissipating, and/or heat signature-reducing material is
operable to protect a person's skin from burns from a
heat-generating article or source. Surprisingly, one embodiment of
the heat blocking or shielding, heat-dissipating and/or heat
signature-reducing material layer was discovered when it was in a
person's hand but they were not burned by a heat gun when holding
the material in hand, between the heat gun and skin. It was later
tested and proved completely heat-resistant, heat-shielding, and/or
heat-dissipating up to temperatures of heat guns (up to about 1,000
degrees Fahrenheit), propane torches (up to about 3,623 degrees
Fahrenheit), and oxygen-fed torches (up to about 5,110 degrees
Fahrenheit). These surprising test results combined with other
trials generated the embodiments of the present invention and the
particular examples that are described herein, in particular for
linings or coatings that are constructed and configured especially
for heat blocking or shielding, heat-dissipating and/or heat
signature-reducing material layer or coating applied to objects for
protecting an article from any external heat source, as well as
dissipating heat produced by heat-producing devices and their
batteries.
FIG. 1A and FIG. 1B are cross-sectional views of examples of
structures that include the material for dissipating heat from
and/or reducing heat signature of electronic devices and/or
clothing. The heat-dissipating and/or heat signature-reducing
material can be used in combination with, for example, one or two
substrates. For example, FIG. 1A shows a structure 100 that
includes a heat-dissipating and/or heat signature-reducing layer
120. The heat-dissipating and/or heat signature-reducing layer 120
can be sandwiched between a first substrate 125 and a second
substrate 130.
The heat-dissipating and/or heat signature-reducing layer 120 can
be any material that is suitable for dissipating heat from and/or
reducing the heat signature of electronic devices and/or clothing.
The heat-dissipating and/or heat signature-reducing layer 120 can
be from about 20 .mu.m thick to about 350 .mu.m thick in one
example. In particular embodiments, the heat-dissipating and/or
heat signature-reducing layer 120 can have a thickness ranging from
about 1 mil to about 6 mil, including, but not limited to, 1, 2, 3,
4, 5, and 6 mil, or about 25 .mu.m to about 150 .mu.m, including,
but not limited to, 25, 50, 75, 100, 125, and 150 .mu.m. Examples
of the heat-dissipating and/or heat signature-reducing layer 120
include anti-static, anti-radio frequency (RF), and/or
anti-electromagnetic interference (EMI) materials, such as copper
shielding plastic or copper particles bonded in a polymer matrix,
as well as anti-tarnish and anti-corrosion materials. A specific
example of the heat-dissipating and/or heat signature-reducing
layer 120 is the anti-corrosive material used in Corrosion
Intercept Pouches, catalog number 034-2024-10, available from
University Products Inc. (Holyoke, Mass.). The anti-corrosive
material is described in U.S. Pat. No. 4,944,916 to Franey, which
is incorporated by reference in its entirety. Such materials can
comprise copper shielded or copper impregnated polymers including,
but not limited to, polyethylene, low-density polyethylene,
high-density polyethylene, polypropylene, and polystyrene. In
another embodiment, the heat shielding or blocking,
heat-dissipating, and/or heat signature-reducing layer is a polymer
with aluminum and/or copper particles incorporated therein. In
particular, the surface area of the polymer with aluminum and/or
copper particles incorporated therein preferably includes a large
percent by area of copper and/or aluminum. By way of example and
not limitation, the surface area of the heat-dissipating and/or
heat signature-reducing layer includes about 25% by area copper
and/or aluminum, 50% by area copper and/or aluminum, 75% by area
copper and/or aluminum, or 90% by area copper and/or aluminum. In
one embodiment, the heat shielding or blocking, heat-dissipating,
and/or heat signature-reducing layer is substantially smooth and
not bumpy. In another embodiment, the heat shielding or blocking,
heat-dissipating, and/or heat signature-reducing layer is not flat
but includes folds and/or bumps to increase the surface area of the
layer. Alternatively, the heat-shielding or blocking,
heat-dissipating and/or heat signature-reducing layer 120 includes
a fabric having at least one metal incorporated therein or thereon.
The fabric further includes a synthetic component, such as by way
of example and not limitation, a nylon, a polyester, or an acetate
component. Preferably, the at least one metal is selected from the
group consisting of copper, nickel, aluminum, gold, silver, tin,
zinc, or tungsten.
The first substrate 125 and the second substrate 130 can be any
flexible or rigid substrate material. An example of a flexible
substrate is any type of fabric. Examples of rigid substrates
include, but are not limited to, glass, plastic, and metal. A rigid
substrate may be, for example, the housing of any device. In one
example, both the first substrate 125 and the second substrate 130
are flexible substrates. In another example, both the first
substrate 125 and the second substrate 130 are rigid substrates. In
yet another example, the first substrate 125 is a flexible
substrate and the second substrate 130 is a rigid substrate. In
still another example, the first substrate 125 is a rigid substrate
and the second substrate 130 is a flexible substrate. Further, the
first substrate 125 and the second substrate 130 can be
single-layer or multi-layer structures.
In structure 100 of FIG. 1A, the heat-shielding or blocking,
heat-dissipating and/or heat signature-reducing layer 120, the
first substrate 125, and the second substrate 130 are bonded or
otherwise attached together, by way of example and not limitation,
by adhesive, stitching, hook-and-loop fastener system). In another
example and referring now to FIG. 1B, in a structure 105, the first
substrate 125 is bonded to one side of the heat shielding or
blocking, heat-dissipating, and/or heat signature-reducing layer
120, whereas the second substrate 130 is not bonded or otherwise
attached to the other side of the heat shielding or blocking,
heat-dissipating, and/or heat signature-reducing layer 120. In yet
another example and referring now to FIG. 1C, in a structure 110,
the first substrate 125 is provided loosely against one side of the
heat shielding or blocking, heat-dissipating, and/or heat
signature-reducing layer 120 and the second substrate 130 is
provided loosely against the other side of the heat-dissipating
and/or heat signature-reducing layer 120. The first substrate 125
and the second substrate 130 are not bonded or otherwise attached
to the heat shielding or blocking, heat-dissipating, and/or heat
signature-reducing layer 120. In still another example and
referring now to FIG. 1D, in a structure 115, the heat shielding or
blocking, heat-dissipating, and/or heat signature-reducing layer
120 is provided in combination with the first substrate 125 only,
either bonded or loosely arranged. In FIG. 1D, if the two layers
are loosely arranged, the heat-dissipating and/or heat
signature-reducing layer 120 is not bonded or otherwise attached to
the first substrate 125. The presently disclosed material is not
limited to the structures 100, 105, 110, 115. These structures are
exemplary only.
The heat-shielding or blocking, heat-dissipating and/or heat
signature-reducing layer 120 can be used as a protective shield
against heated objects and also for reducing the heat signature of
objects. For example, in military applications, the heat shielding
or blocking, heat-dissipating, and/or heat signature-reducing layer
120 can be used to reduce the heat signature of devices or clothing
for military personnel to reduce the risk of their being detected
by thermal imaging.
Other examples of applications and/or uses of the heat-shielding or
blocking, heat-dissipating and/or heat signature-reducing layer 120
include, but are not limited to, insulating battery packs, for
example in any battery housing or electronic device housing;
protecting device and/or users from undesirable external heat;
forming sandwich structures; form fitting to a particular device;
enclosing electronic materials to prevent corrosion or feathering;
medical applications to protect patients from heated devices used
in surgical procedures, for example, in robotics (e.g., for use in
disposable, sterile drapes); forming solar panels; lining tents
(e.g., to prevent heat from going in or out); forming heat shields
or guards for mufflers on, for example, motorcycles, lawn mowers,
leaf blowers, or weed eaters; lining gloves to protect from flames,
handling ice, and/or for preparing food (including pastry
preparation).
Other examples of protective flexible heat shielding applications
in which the heat-dissipating and/or heat signature-reducing layer
120 can be used include gloves (e.g., fire pit gloves,
gloves/forearm shields for operating two-stroke engine yard
equipment), integrated in uniforms (e.g., nurses/scrub technicians
in operating rooms vs. electro cautery), motorcyclist (clothing)
protection from tail pipes, protective shielding in radio pouches
(e.g., protecting person from radio heat, protecting radio from
heating battery, protecting battery from heating radio, protecting
battery from external heat sources), protection on the bottom of a
laptop (inside the laptop housing), protection layer from heat of
laptop for laps (e.g., lap tray) and expensive furniture (e.g.,
furniture pad), and portable protective heat shield (e.g., protect
sensitive electronics and persons, varies in sizes).
FIG. 2A is a perspective view of a radio holder article 200 into
which the heat-shielding or blocking, heat-dissipating and/or heat
signature-reducing layer 120 is installed. The radio holder article
200 is an example of equipment that may be used by military
personnel. The radio holder article 200 is but one example of using
the heat-shielding or blocking, heat-dissipating and/or heat
signature-reducing layer 120 for dissipating heat from and/or
reducing the heat signature of an article. Military radios often
get hot and can cause burns to the user.
The radio holder article 200 can be removably held in a pouch 210
and worn on a user's belt 230. FIG. 2B is a view of the radio
holder article 200 removed from the pouch 210. In this example, a
structure, such as the structure 115 of FIG. 1D, is formed
separately and then inserted into the pouch 210 of the radio holder
article 200. In another example, in the case of the structure 105
of FIG. 1B, the radio holder article 200 itself serves as the
second substrate 130. This allows the radio holder article 200 to
be easily removed from the pouch 210. It also provides for
retrofitting the pouch with heat protection from the heat-shielding
or blocking, heat-dissipating and/or heat signature-reducing
material layer or coating.
Alternatively, the radio holder article 200 is permanently held in
the pouch 210. The pouch 210 is formed using a structure, such as
the structure 100 of FIG. 1A. The pouch 210 includes a pouch
attachment ladder system (PALS) adapted to attach the pouch to a
load-bearing platform (e.g., belt, rucksack, vest). In a preferred
embodiment, the pouch 210 is MOLLE-compatible. "MOLLE" means
Modular Lightweight Load-carrying Equipment, which is the current
generation of load-bearing equipment and backpacks utilized by a
number of NATO armed forces.
In this example, the heat-shielding or blocking, heat-dissipating
and/or heat signature-reducing layer 120 protects the user from
heat from the radio (not shown), the heat shielding or blocking,
heat-dissipating, and/or heat signature-reducing layer 120 protects
the radio (not shown) from any external heat source (e.g., a hot
vehicle), and the heat shielding or blocking, heat-dissipating,
and/or heat signature-reducing layer 120 reduces the heat signature
of the radio (not shown).
In a preferred embodiment, the substrate 225 can be formed of any
flexible, durable, and waterproof or at least water resistant
material. For example, the substrate 225 can be comprised of
polyester, polyvinyl chloride (PVC)-coated polyester, vinyl-coated
polyester, nylon, canvas, PVC-coated canvas, or polycotton canvas.
The exterior finish of the substrate 225 can be any color, such as
white, brown, or green, or any pattern, such as camouflage, as
provided herein, or any other camouflage in use by the
military.
Representative camouflages include, but are not limited to,
universal camouflage pattern (UCP), also known as ACUPAT or ARPAT
or Army Combat Uniform; MultiCam, also known as Operation Enduring
Freedom Camouflage Pattern (OCP); Universal Camouflage Patter-Delta
(UCP-Delta); Airman Battle Uniform (ABU); Navy Working Uniform
(NWU), including variants, such as, blue-grey, desert (Type II),
and woodland (Type III); MARPAT, also known as Marine Corps Combat
Utility Uniform, including woodland, desert, and winter/snow
variants; Disruptive Overwhite Snow digital camouflage, and
Tactical Assault Camouflage (TACAM).
FIG. 3 and FIG. 4 are a perspective view and an exploded view,
respectively, of a flexible solar panel article 300 into which the
heat-shielding or blocking, heat-dissipating and/or heat
signature-reducing layer 120 is installed. The flexible solar panel
article 300 is another example of equipment that may be used by
military personnel. The flexible solar panel article 300 is but
another example of using the heat shielding or blocking,
heat-dissipating and/or heat signature-reducing layer 120 for
shielding or blocking external heat to, and/or dissipating heat
from and/or reducing the heat signature of an article.
In this example, the flexible solar panel article 300 is a flexible
solar panel that can be folded up and carried in a backpack and
then unfolded and deployed as needed. The flexible solar panel
article 300 is used, for example, to charge rechargeable batteries
or to power electronic equipment directly.
The flexible solar panel article 300 is a multilayer structure that
includes multiple solar modules 322 mounted on a flexible
substrate, wherein the flexible substrate with the multiple solar
modules 322 is sandwiched between two layers of fabric. Windows are
formed in at least one of the two layers of fabric for exposing the
solar modules 322.
A hem 324 may be provided around the perimeter of the flexible
solar panel article 300. In one example, the flexible solar panel
article 300 is about 36.times.36 inches. The output of any
arrangement of solar modules 322 in the flexible solar panel
article 300 is a direct current (DC) voltage. Accordingly, the
flexible solar panel article 300 includes an output connector 326
that is wired to the arrangement of solar modules 322. The output
connector 326 is used for connecting any type of DC load to the
flexible solar panel article 300. In one example, the flexible
solar panel article 300 is used for supplying power a device, such
as a DC-powered radio. In another example, the flexible solar panel
article 300 is used for charging a battery.
The flexible solar panel article 300 includes a solar panel
assembly 328 that is sandwiched between a first fabric layer 330
and a second fabric layer 332. The first fabric layer 330 and the
second fabric layer 332 can be formed of any flexible, durable, and
substantially waterproof or at least water resistant material, such
as but not limited to, polyester, PVC-coated polyester,
vinyl-coated polyester, nylon, canvas, PVC-coated canvas, and
polycotton canvas. The first fabric layer 330 and the second fabric
layer 332 can be any color or pattern, such as the camouflage
pattern shown in FIG. 3 and FIG. 4.
The solar panel assembly 328 of the flexible solar panel article
300 includes the multiple solar modules 322 mounted on a flexible
substrate 334. A set of windows or openings 340 is provided in the
first fabric layer 330 for exposing the faces of the solar modules
322. The flexible substrate 334 is formed of a material that is
lightweight, flexible (i.e., foldable or rollable), printable, and
substantially waterproof or at least water resistant.
In the flexible solar panel article 300, the heat-dissipating
and/or heat signature-reducing layer 120 is incorporated into the
layers of fabric that form the flexible solar panel article 300, in
similar fashion to the structure 100 of FIG. 1A. Namely, the
heat-dissipating and/or heat signature-reducing layer 120 is
provided at the back of solar modules 322, between the flexible
substrate 334 and the second fabric layer 332. In this example, the
first fabric layer 330, the flexible substrate 334, the
heat-dissipating and/or heat signature-reducing layer 120, and the
second fabric layer 332 are held together by stitching and/or by a
hook-and-loop fastener system.
In this example, the heat-shielding or blocking, heat-dissipating
and/or heat signature-reducing layer 120 protects the user from
heat from the back of the flexible solar panel article 300, the
heat-shielding or blocking, heat-dissipating and/or heat
signature-reducing layer 120 protects the back of the flexible
solar panel article 300 from any external heat source (not shown),
and the heat-dissipating and/or heat signature-reducing layer 120
reduces the heat signature of the flexible solar panel article
300.
FIGS. 5-7 are perspective views of a portable battery pack 500 into
which the heat dissipating and/or heat signature-reducing material
is installed. The portable battery pack 500 is an example of
equipment that may be used by military personnel. The portable
battery pack 500 is but one example of using the heat-shielding or
blocking, heat-dissipating and/or heat signature-reducing layer 120
for dissipating heat from and/or reducing the heat signature of an
article. In a preferred embodiment, the portable battery pack
comprises a portable battery pack such as that disclosed in US
Publication No. 20160118634, which is incorporated by reference in
its entirety.
Portable battery pack 500 comprises a pouch 510 for holding a
battery 550. Pouch 510 is a wearable pouch or skin that can be
sized in any manner that substantially corresponds to a size of
battery 550. In one example, pouch 510 is sized to hold a battery
550 that is about 9.75 inches long, about 8.6 inches wide, and
about 1 inch thick.
Pouch 510 is formed of any flexible, durable, and substantially
waterproof or at least water resistant material. For example, pouch
510 can be formed of polyester, polyvinyl chloride (PVC)-coated
polyester, vinyl-coated polyester, nylon, canvas, PVC-coated
canvas, or polycotton canvas. The exterior finish of pouch 510 can
be any color, such as white, brown, or green, or any pattern, such
as camouflage, as provided herein, or any other camouflage in use
by the military. For example, in FIG. 5, FIG. 6, and FIG. 7, pouch
510 is shown to have a camouflage pattern.
Representative camouflages include, but are not limited to,
universal camouflage pattern (UCP), also known as ACUPAT or ARPAT
or Army Combat Uniform; MultiCam, also known as Operation Enduring
Freedom Camouflage Pattern (OCP); Universal Camouflage Patter-Delta
(UCP-Delta); Airman Battle Uniform (ABU); Navy Working Uniform
(NWU), including variants, such as, blue-grey, desert (Type II),
and woodland (Type III); MARPAT, also known as Marine Corps Combat
Utility Uniform, including woodland, desert, and winter/snow
variants; Disruptive Overwhite Snow digital camouflage, and
Tactical Assault Camouflage (TACAM).
Pouch 510 has a first side 512 and a second side 514. Pouch 510
also comprises an opening 516, which is the opening through which
battery 550 is fitted into pouch 510. In one example, opening 516
is opened and closed using a zipper, as such pouch 510 includes a
zipper tab 518. Other mechanisms, however, can be used for holding
opening 516 of pouch 510 open or closed, such as, a hook and loop
system (e.g., Velcro.RTM.), buttons, snaps, hooks, and the like.
Further, an opening 520 (see FIG. 6, FIG. 7, FIG. 9) is provided on
the end of pouch 510 that is opposite opening 516. For example,
opening 520 can be a 0.5-inch long slit or a 0.75-inch long slit in
the edge of pouch 510.
In one embodiment, the pouch is a multi-layer structure, such as
the structure 100 of FIG. 1A, including at least one layer of the
heat-dissipating and/or heat signature-reducing layer. In this
embodiment, the heat-dissipating and/or heat signature-reducing
layer is permanently attached to the pouch. Alternatively, a
structure, such as the structure 115 of FIG. 1D, is formed
separately and then inserted into the pouch 510 of the portable
battery pack 500. This allows the user to retrofit an existing
pouch with heat protection. The retrofit structure comprises a
structure, such as the structure 115 of FIG. 1D, for protecting the
first side 512 and/or the second side 514. The retrofit structure
comprises a large structure that is operable to wrap around the
battery 550 in an alternative embodiment.
In one example, battery 550 is a rechargeable battery that
comprises two leads 552 (e.g., leads 552a, 552b). Each lead 552 can
be used for both the charging function and the power supply
function. In other words, leads 552a, 552b are not dedicated to the
charging function only or the power supply function only, both
leads 552a, 552b can be used for either function at any time. In
one example, one lead 552 can be used for charging battery 550
while the other lead 552 can be used simultaneously for powering
equipment, or both leads 552 can be used for powering equipment, or
both leads 552 can be used for charging battery 550.
With respect to using battery 550 with pouch 510, first the user
unzips opening 516, then the user inserts one end of battery 550
that has, for example, lead 552b through opening 516 and into the
compartment inside pouch 510. At the same time, the user guides the
end of lead 552b through opening 520, which allows the housing of
battery 550 to fit entirely inside pouch 510, as shown in FIG. 5.
Lead 552a is left protruding out of the unzipped opening 516. Then
the user zips opening 516 closed, leaving zipper tab 518 snugged up
against lead 552a, as shown in FIG. 6 and FIG. 7. Namely, FIG. 6
shows portable battery pack 500 with side 512 of pouch 510 up,
whereas FIG. 7 shows portable battery pack 500 with side 514 of
pouch 510 up.
Pouch 510 of portable battery pack 500 can be MOLLE-compatible.
"MOLLE" means Modular Lightweight Load-carrying Equipment, which is
the current generation of load-bearing equipment and backpacks
utilized by a number of NATO armed forces. Namely, pouch 510
incorporates a pouch attachment ladder system (PALS), which is a
grid of webbing used to attach smaller equipment onto load-bearing
platforms, such as vests and backpacks. For example, the PALS grid
consists of horizontal rows of 1-inch (2.5 cm) webbing, spaced
about one inch apart, and reattached to the backing at 1.5-inch
(3.8 cm) intervals. Accordingly, a set of straps 522 (e.g., four
straps 522) are provided on one edge of pouch 510 as shown.
Further, four rows of webbing 524 are provided on side 512 of pouch
510, as shown in FIG. 7. Additionally, four rows of slots or slits
526 are provided on side 514 of pouch 510, as shown in FIG. 7.
FIGS. 8-10 are perspective views of an example of wearable pouch
510 of the portable battery pack 500. Namely, FIG. 8 shows details
of side 512 of pouch 510 and of the edge of pouch 510 that includes
opening 516. FIG. 8 shows opening 516 in the zipper closed state.
Again, four rows of webbing 524 are provided on side 512 of pouch
510. FIG. 9 also shows details of side 512 of pouch 510, but
showing the edge of pouch 510 that includes opening 520. FIG. 10
shows details of side 514 of pouch 510 and shows the edge of pouch
510 that includes opening 516. FIG. 10 shows opening 516 in the
zipped closed state. Again, four rows of slots or slits 526 are
provided on side 514 of pouch 510.
FIG. 11 illustrates various other views of wearable pouch 510 of
the portable battery pack 500. Namely, FIG. 11 shows a plan view A,
which is side 512 of pouch 510; a plan view B, which is side 514 of
pouch 510; a side view; an end view A, which is the non-strap end
of pouch 510; and an end view B, which is the strap 512-end of
pouch 510.
FIG. 12A is an exploded view of an example of battery 550 of the
portable battery pack 500. Battery 550 includes a battery element
564 that is housed between a battery cover 554 and a back plate
562. Battery element 564 supplies leads 552a, 552b. In one example,
the output of battery element 564 can be from about 5 volts DC to
about 90 volts DC at from about 0.25 amps to about 10 amps.
FIG. 12B illustrates an exploded view of an example of a battery
550 of the portable battery pack 500 into which the heat
dissipating and/or heat signature-reducing material is installed.
Battery 550 includes a battery element 564 that is housed between a
battery cover 554 and a back plate 562. A first heat-dissipating
and/or heat signature-reducing layer 570 is between the battery
cover 554 and the battery element 564. The first heat-dissipating
and/or heat signature-reducing layer 570 protects the battery from
external heat sources (e.g., a hot vehicle). A second
heat-dissipating and/or heat signature-reducing layer 572 is
between the battery element 564 and the back plate 562. The second
heat-dissipating and/or heat signature-reducing layer 572 protects
the user from heat given off by the battery element 564.
Battery cover 554 comprises a substantially rectangular compartment
556 that is sized to receive battery element 564. A top hat style
rim 558 is provided around the perimeter of compartment 556.
Additionally, two channels 560 (e.g., channels 560a, 560b) are
formed in battery cover 554 (one on each side) to accommodate the
wires of leads 552a, 552b passing therethrough.
Battery cover 554 and back plate 562 can be formed of plastic
using, for example, a thermoform process or an injection molding.
Back plate 562 can be mechanically attached to rim 558 of battery
cover 554 via, for example, an ultrasonic spot welding process or
an adhesive. Additionally, a water barrier material, such as
silicone, may be applied to the mating surfaces of rim 558 and back
plate 562. Battery cover 554, back plate 562, and battery element
564 can have a slight curvature or contour for conforming to, for
example, the user's vest, backpack, or body armor.
FIG. 13 and FIG. 14 are perspective views of battery 550 of the
portable battery pack 500 when fully assembled. Namely, FIG. 13
show a view of the battery cover 554-side of battery 550, while
FIG. 14 shows a view of the back plate 562-side of battery 550.
FIG. 15 illustrates an exploded view of an example of a housing of
a battery 1500 into which the heat-shielding or blocking,
heat-dissipating and/or heat signature-reducing material is
provided as a coating or layer. The battery 1500 is an example of
equipment that may be used by military personnel. The battery 1500
is but one example of using the heat-shielding or blocking,
heat-dissipating and/or heat signature-reducing layer 120 for
dissipating heat from and/or reducing the heat signature of an
article.
The battery 1500 includes a lid 1502 and a base 1504. The base 1504
has a mounting plaque 1510 for mounting a latch on the base. The
base 1504 has a recessed hole 1508 for a connector on both sides of
the base 1504. The lid 1502 includes holes 1512 to attach the lid
to the base 1504. The base 1504 includes holes 1514 to attach the
lid to the base of the housing. Screws (not shown) are placed
through holes 1512 and 1514 to attach the lid to the base. The lid
1502 includes a hole 1516 for mounting a connector.
In one embodiment, the battery housing or base 1504 with sides
depending upwards therefrom is a unitary and integrally formed
piece of plastic formed via injection molding. Advantageously, when
the heat-shielding or blocking, heat-dissipating and/or heat
signature-reducing material is utilized in conjunction with the
base, the base can be manufactured from much thinner plastic than
in prior art battery housings because the heat-shielding or
blocking, heat-dissipating and/or heat signature-reducing material
effectively blocks, shields from, and dissipates heat. In contrast,
prior art plastic battery housings require thicker plastic to
provide heat blocking, shielding, and dissipation. When used in
conjunction with the heat-shielding or blocking, heat-dissipating
and/or heat signature-reducing material, the thin plastic material
requirement of the present invention provides for cost savings over
the prior art. In fact, some embodiments of the housing of the
present invention use materials and types of materials which
traditionally have been disfavored because of the heat generated
from batteries. Such materials include by way of example not
limitation, aluminum, titanium, nickel, magnesium, microlattice
metals, composite metal foams, and combinations thereof. Notably,
many of these materials were previously disfavored for the base
because of the heat transfer and dissipation from the batteries.
Materials which provide other advantages such as bullet resistance,
such as composite metal foams, are also used for the base in one
embodiment of the present invention.
The battery housing or base 1504 for removably holding at least one
battery is coated with a paint 1506 for reducing electromagnetic
interference. In a preferred embodiment, the paint 1506 includes
copper. Although the base 1504 of the at least one battery 1500 is
coated with the paint 1506, which functionally protects the bottom
and sides of the at least one battery from external heat, the top
of the battery is exposed to external heat when attached to heat
generating equipment (e.g., radio). Since external heat can damage
the battery and/or cause it to overheat, the heat-shielding or
blocking, heat-dissipating and/or heat signature-reducing material
layer or coating is functionally constructed and configured within
the interior of the housing or base to protect the removable
batteries disposed therein. In this particular example, the radio
generates a significant heat profile and the heat-shielding
material is operable to block that external heat emanating from the
radio. The material is further functional to dissipate heat
generated by the at least one battery during operation of the
radio, which draws power from the at least one battery, and reduces
the heat signature of the at least one battery disposed within the
housing or base.
In another example of embodiments of the present invention, the
heat-shielding or blocking, heat-dissipating and/or heat
signature-reducing material completely covers the interior of a
housing having a plurality of battery cells removably disposed
therein. Other examples include a heat-shielding or blocking,
heat-dissipating and/or heat signature-reducing material layer
having anti-static, anti-radio frequency (RF), anti-electromagnetic
interference (EMI), anti-tarnish, and/or anti-corrosion materials
and properties that effectively protect battery-operated devices
and/or the batteries that power them from damage or diminished
operation.
The battery housing or base 1504 includes a plurality of sealed
battery cells or individually contained battery cells, i.e.
batteries with their own casings, removably disposed therein. In a
preferred embodiment, the battery cells are electrochemical battery
cells, and more preferably, include lithium ion rechargeable
batteries. In one embodiment the batteries are 18650 cylindrical
cells. The plurality of battery cells may be constructed and
configured in parallel, series, or a combination. Preferably, the
plurality of electrochemical battery cells are removably disposed
within the base or battery housing or container. For example, the
plurality of battery cells can be replaced if they no longer hold a
sufficient charge.
FIG. 16 illustrates a view of an example of a battery base 1504.
The base 1504 is shown with a latch 1520. The latch 1514 is
operable to attach the battery 1500 to a military radio (e.g.,
AN/PRC-117G) with a corresponding catch. A dust cap 1518 is
attached to the battery base 1504 via a lanyard 1516 attached to
the mounting plaque. The length of the lanyard 1516 is such that no
part of the dust cap 1512 is capable of moving underneath the
battery 1500. Batteries often have the dust cap attached to the
housing via a dress nut, which allows the dust cap to move
underneath the battery. When the dust cap is underneath the
battery, the battery (and any equipment attached to the battery)
may become unstable and tip over. If the dust cap is underneath the
battery, it may lead to the dust cap being torn from the housing.
The battery would no longer be protected from dust and other
environmental contaminants.
FIG. 17 illustrates another view of an example of a battery base
1504. In a preferred embodiment, the recessed hole 1508 includes a
flat side 1530 for installing a connector with a keyway. A right
angle cable is used to connect the battery to external power
consuming devices and/or external power sources. The keyway ensures
that the right angle cable does not interfere with latches used to
attach the battery to the radio. The keyway in FIG. 17 forces the
cable to a 30.0.degree. angle. Other angles are compatible with the
present invention.
FIGS. 18A-D illustrate various other views of the lid.
FIGS. 19A-F illustrate various other views of the base.
FIG. 20 illustrates a view of a BA-5590 female connector. In a
preferred embodiment, the BA-5590 female connector is installed in
the hole 1516 of the lid.
FIG. 21 illustrates a block diagram of a portable power case into
which the heat dissipating and/or heat signature-reducing material
is installed. The portable power case 2100 is an example of
equipment that may be used by military personnel. The portable
power case 2100 is but one example of using the heat-shielding or
blocking, heat-dissipating and/or heat signature-reducing layer 120
for dissipating heat from and/or reducing the heat signature of an
article.
The portable power case 2100 has four access ports 2120A-2120D and
two USB ports 2122A-2122B. The portable power case 2100 is operable
to connect to an amplifier 2104 through an access port (e.g.,
2120A). The amplifier 2104 connects to a radio 2102. The portable
power case 2100 is operable to be charged using a solar panel 2106
when connected to an access port (e.g., 2120B). The portable power
case 2100 is operable to charge a wearable battery 2108. The
portable power case 2100 and wearable battery 2108 are connected
through a DC-DC converter cable 2110 that is in contact with an
access port (e.g., 2120C). The portable power case 2100 is operable
to be charged using a vehicle battery 2112. The vehicle battery
2112 is operable to charge the portable power case 2100 for a brief
period after the ignition of the vehicle is turned off. The system
includes a battery protector 2114 connected to an access port
(e.g., 2120D) to prevent the vehicle battery from being drained.
The battery protector 2114 is connected to the access port 2120D
through a DC-DC converter cable 2116. The USB ports 2122A-2122B are
operable to charge electronic devices, including, but not limited
to, a mobile phone 2130 and/or a tablet 2132.
In a preferred embodiment, the amplifier is a 50 W wideband
vehicular amplifier adapter (RF-7800UL-V150 by Harris Corporation)
or a power amplifier for the Falcon III VHF handheld radio
(RF-7800V-V50x by Harris Corporation). In a preferred embodiment,
the radio is a PRC-117G. Alternative radios and/or amplifiers are
compatible with the present invention.
FIG. 22 illustrates a block diagram showing the inside of one
embodiment of the portable power case 2100. The portable power case
2100 is comprised of two batteries 2202A-2202B and three batteries
2204A-2204C. In a preferred embodiment, the batteries 2202A-2202B
are 29.4V lithium ion rechargeable batteries in a housing for
mating with a PRC-117G radio. In a preferred embodiment, the
batteries 2204A-2204C are 29.4V lithium ion rechargeable batteries
in a housing for mating with a PRC-117F radio. Alternative
voltages, housings, and/or number of batteries are compatible with
the present invention. The batteries 2202A-2202B and 2204A-2204C
are connected to a PCB 2206. In a preferred embodiment, the
batteries 2202A-2202B and 2204A-2204C include a heat-dissipating
layer between the lid and the plurality of electrochemical battery
cells.
FIG. 23 illustrates a block diagram of the connections to the PCB.
The PCB 2206 has four inputs. Batteries 2202A and 2202B are in
parallel with each other and connected to the PCB at INPUT 1.
Battery 2204A is connected to the PCB at INPUT 2. Battery 2204B is
connected to the PCB at INPUT 3. Battery 2204C is connected to the
PCB at INPUT 4. The PCB 2206 has five outputs. OUTPUT 1 powers
access port 2120A, OUTPUT 2 powers access port 2120B, OUTPUT 3
powers access port 2120C, OUTPUT 4 powers access port 2120D, and
OUTPUT USB powers USB ports 2122A and 2122B.
In a preferred embodiment, the PCB uses ferrite beads to provide
EMI shielding. The PCB also uses capacitors to protect the
batteries.
The portable power case is enclosed in a hard case (e.g., Pelican
1500) in a preferred embodiment. The hard case is comprised of
polypropylene in one embodiment. FIG. 24 illustrates a view of the
exterior of the portable power case. The case includes a top
portion 2602 and a bottom portion 2604. A base for mounting at
least one amplifier and at least one radio 2606 is attached to the
top portion 2602 through shock absorbing cylinders 2608. The case
includes latches 2610 for securing the contents of the case, a
pressure purge valve 2612, and a handle 2614. The latches include
rescue tape in a preferred embodiment to prevent the latches from
rattling. A cap 2616 is provided to protect the USB ports. A base
for securing the portable power case to a vehicle 2620 is attached
to the bottom portion 2604 through shock absorbing cylinders
2618.
In a preferred embodiment, the base for mounting at least one
amplifier and at least one radio 2606, the shock absorbing
cylinders 2618, and the base for securing the portable power case
to a vehicle 2620 are comprised of a shock mount interface assembly
(e.g., Harris 12050-3050-01). Alternative mounts are compatible
with the present invention.
FIG. 25 illustrates a view of the case with the cap (not shown)
removed to show the USB ports. USB ports 2122A and 2122B are
accessible on the front of the case.
The hard case is lined with foam in one embodiment. Additionally or
alternatively, the case is lined with a material that is resistant
to heat and/or electromagnetic interference. FIG. 26 shows one
example of the portable power case 2100 lined with material
resistant to heat 120. The amplifier and radio give off a
significant amount of heat. The heat resistant material prevents
heat transfer from the amplifier and radio to the batteries. If a
lithium ion battery overheats, it reduces performance of the
battery, reduces the life span of the battery, and may result in a
fire.
Additionally, the heat resistant material may also be
anti-electromagnetic interference material. The
anti-electromagnetic interference material lining creates a Faraday
cage and prevents disruption by electromagnetic radiation. In an
alternative embodiment, the case may be coated with an
electromagnetic interference and/or radio frequency interference
shielding paint including copper, silver, nickel, and/or
graphite.
The portable power case provides for modularity that allows the
user to disassemble and selectively remove the batteries installed
within the portable power case housing that is lined with the
heat-shielding or blocking, heat-dissipating and/or heat
signature-reducing layer in a preferred embodiment. The modularity
allows the user to comply with Survival, Evasion, Resistance, and
Escape (SERE) training. In case of attack, each of the batteries
can be used to power the at least one radio and/or the at least one
amplifier, as well as other gear.
The access ports are shown in FIG. 27A. The access ports are
preferably staggered vertically and horizontally to allow for easy
access to the ports. As shown in FIG. 27B, the preferred embodiment
includes a keyway (shown as a flat portion of the connector) to
ensure correct orientation of cables. In a preferred embodiment,
the cables connected to the access ports located on the top row
orient downwards and the cables connected to the access ports
located on the bottom row orient upwards. Alternatively, the cables
connected to the access ports located on the top row orient
downwards and the cables connected to the access ports located on
the bottom row orient downwards. A gasket 2702 is provided around
each of the access ports to seal the interior of the case from the
external environment.
The four access ports are on the left side of the case in a
preferred embodiment. FIG. 28 illustrates a block diagram of a
portable power case in an ATV with three passengers. The ATV 2800
has a steering wheel 2802 and a seat for a driver 2804. A seat for
a first passenger 2806 is to the right of the driver. The first
passenger is responsible for maintaining the security of the right
side of the ATV. A seat for a second passenger 2808 is behind the
driver. The second passenger is responsible for maintaining the
security of the left side of the ATV. The location of the first
passenger and the second passenger allow for 360 degree visual
coverage of the landscape surrounding the ATV. The portable power
case 2100 is located to the right of the second passenger. Placing
the access ports on the left side of the case prevents the second
passenger and/or gear from knocking the cables connected to the
case loose from the access ports. The trunk 2810 is available for
storing additional gear.
FIG. 29 illustrates a block diagram of a portable power case in an
ATV with four passengers. The ATV 2800 has a steering wheel 2802
and a seat for a driver 2804. A seat for a first passenger 2806 is
to the right of the driver. A seat for a second passenger 2808 is
behind the driver. The second passenger is responsible for
maintaining the security of the left side of the ATV. A seat for a
third passenger 2812 is to the right of the seat for the third
passenger 2808. The portable power case 2100 is placed in the trunk
2810.
The portable power case has two USB ports for charging electronic
devices (e.g., mobile phone, tablet, smartphone, camera, global
positioning system devices (GPS), thermal imaging devices, weapon
optics, watches, satellite phones, defense advanced GPS receivers)
in a preferred embodiment. The USB ports are preferably located on
the front side of the case. Alternatively, the USB ports are
located on the left or right side of the case.
The system allows the portable power case to charge using the
vehicle battery after the ignition is turned off. The system
includes a battery protector to prevent users from being stranded
due to a drained vehicle battery.
FIG. 30 illustrates a block diagram of the battery protector. The
battery protector includes INPUT from the vehicle battery 2112 and
OUTPUT to the DC-DC converter 2116. A green LED 3002 and a red LED
3004 provide visual information regarding the current charge
status. The battery protector includes a rotary switch 3008 to
select a desired time or voltage setting.
In one embodiment, the battery protector is a timer set to a time
where the load will not drain the battery (e.g., 2 minutes, 15
minutes, 30 minutes, 1 hour, 2 hours, 3 hours, 4 hours, 5 hours, 8
hours, or 12 hours). Additionally or alternatively, the battery
protector is a low voltage disconnect (LVD) that automatically
disconnects the load when the vehicle battery voltage falls below a
set DC voltage (e.g., 10.6V, 10.8V, 11.0V, 11.2V, 11.4V, 11.6V,
11.8V, 12.0V, 12.1V, or 12.2V). In one embodiment, the battery
protector automatically reconnects the load when the battery
voltage returns to a normal value (e.g., above the set DC voltage)
after charging.
The battery protector has over voltage protection that
automatically disconnects the load when the battery protector
detects a voltage higher than a set DC voltage (e.g., above 16V) in
a preferred embodiment. In one embodiment, the battery protector
automatically reconnects the load when the detected voltage falls
below the set DC voltage (e.g., below 16V).
The battery protector includes an emergency override switch 3006 in
one embodiment. This allows the load to charge using the vehicle
battery for an additional period of time (e.g., 15 minutes) in an
emergency by overriding a timed out timer.
In a preferred embodiment, the battery protector includes a visual
indicator (e.g., LED lights) to indicate a current status. In one
embodiment, the battery protector has a green LED light to indicate
that the engine is running and the load is charging; a flashing
green LED light to indicate that the vehicle engine is off, the
timer has started, and the load is charging; a flashing red LED
light to indicate that the timer has expired and the load is no
longer charging; a slow flashing red LED light to indicate that the
vehicle battery voltage is below the set DC voltage and the load is
no longer charging; and a solid red light to indicate an
overvoltage condition. The battery protector is preferably
waterproof.
The system also allows the portable power case to charge using at
least one alternating current (AC) adapter. All four access ports
can be used to charge the portable power case. In one embodiment,
the power can be charged in 16 hours using one AC adapter, 8 hours
using two AC adapters, and 4 hours using four AC adapters.
In a preferred embodiment, the at least one AC adapter accepts a
100-240 VAC input and has a DC output of 17.4V. In one embodiment,
the at least one AC adapter has an indicator for the charge state
(e.g., red/orange indicates charging and green indicates
charged).
In a preferred embodiment, the solar panel comprises a combination
signal marker panel and solar panel, such as that disclosed in US
Publication No. 20150200318 and U.S. application Ser. No.
15/390,802, each of which is incorporated by reference in its
entirety.
In a preferred embodiment, the solar cells are comprised of
microsystem enabled photovoltaic (MEPV) material, such as that
disclosed in U.S. Pat. Nos. 8,736,108, 9,029,681, 9,093,586,
9,143,053, 9,141,143, 9,496,448, 9,508,881, 9,531,322, 9,548,411,
9,559,219 and US Publication Nos. 20150114444 and 20150114451, each
of which is incorporated by reference in its entirety. The signal
marker panel is fluorescent orange (or "international orange") on a
first side and cerise on a second side.
The system can be also charged using non-rechargeable batteries
(e.g., BA-5590) and NATO generators.
The wearable battery 2108 is preferably the battery shown in FIG.
12B, wherein the battery is lined with a first layer of the
heat-shielding or blocking, heat-dissipating and/or heat
signature-reducing material and a second layer of the
heat-shielding or blocking, heat-dissipating and/or heat
signature-reducing material, e.g., in a layer or lining, or coating
application.
The above-mentioned examples are provided to serve the purpose of
clarifying the aspects of the invention, and it will be apparent to
one skilled in the art that they do not serve to limit the scope of
the invention. By way of example, the keyway may force the cable at
an angle other than 30.0.degree.. Voltages of batteries may be
different.
The above-mentioned examples are just some of the many
configurations that the mentioned components can take on. All
modifications and improvements have been deleted herein for the
sake of conciseness and readability but are properly within the
scope of the present invention.
* * * * *
References